|||||||||||||||||||||||||||||||||||||||||||||||||||l|||||||||||||||||||||||
`
`U800752432032
`
`(12) United States Patent
`Tierney et al.
`
`[10) Patent N0.:
`
`(45} Date of Patent:
`
`US 7,524,320 32
`*Apr. 28, 2009
`
`(54) MECHANICAL ACTUATOR INTERFACE
`SYSTEM FOR ROBOTIC SURGICAL TOOLS
`
`{56)
`
`References Cited
`1J.S.P.1\'1'1iN'I‘DOCUMENTS
`
`(75)
`
`Inventors: Michael J. Tierney. Pleasanton. CA
`(US); Thomas G. Cooper. Menlo Park.
`CA (US); Chris A. Julian. [.05 Gates.
`CA (U S}: Stephen J. Blamenkranz.
`Redwood City. CA (US); Gary S.
`Guthart. Foster City. CA (U S); Robert
`G. Younge, Porto-la Valley, CA (US)
`
`(73) Aessignee:
`
`Intuitive Surgical. Ine.. Sunnyvale, CA
`(US)
`
`4.038.987 A
`
`8519?? Kotniya
`
`(Continued)
`FOREIGN PATENT DOCUMENTS
`
`JP
`
`7-194610
`
`831995
`
`(Continued)
`OTHER PUBLICATIONS
`
`( * ) Notice:
`
`Subject to any disclaimer. the term of this
`patent is extended or adjusted under 35
`use. 154(b) by 1036 days.
`
`Alexander. Arthur D.. 111.. “Impacts 01"l‘elemartipulation on Modern
`Society." International Centre‘for Mediattimt Sciences. Courses and
`Lectures No. 201. vol. 11. pp. 122-136 (Sep. 5-8, 1973).
`
`This patent
`claimer.
`
`is subject to a terminal dis—
`
`(21) App1.N0.: 10t316,666
`
`(22)
`
`Filed:
`
`Dec. 10., 2002
`
`(65)
`
`Prior Publication Data
`
`US 2003i0083673 Al
`
`May 1. 2003
`
`Related U.S. Application Data
`
`(60) Continuation of application No. 09.929.41.53. filed on
`Aug. 13. 2001. now Pat. No. 7.048.745. which is a
`division of application No. [)9i418.726. filed on Oct.
`15. 1999. now Pat. No. 6.331.181.
`
`[60) Provisional application No. 602'] 1 1.713. filed on Dec.
`8. 1998.
`
`[51)
`
`(2006.01)
`
`Int. Cl.
`A613 19/00
`6061130: 606i1
`(52) U.S. Cl.
`60611.
`[58) Field ofClassification Search
`606130; 700t'259. 260. 263
`Sec application file for complete search history.
`
`{Continued}
`
`Pfitl'ittij? Empower—Eduardo C Robert
`Assistant Exaittiner —.lames 1. Swiger. 11]
`
`(57}
`
`ABSTRACT
`
`Robotic surgical tools. systems. and methods for preparing
`for and performing robotic surgery include a memory
`mounted on the tool. The memory can perform a number of
`functions when the too] is loaded on the too] manipulator:
`first. the memory can provide a signal verifying that the tool
`is compatible with that particular robotic system. Secondly.
`the tool memory may identify the tool-type to the robotic
`system so that the robotic system can reconfigure its program-
`ming. Thirdiy. the memory of the tool may indicate too]—
`specific information. including measured calibration offsets
`indicating misalignment of the tool drive system.
`tool life
`data. orthe like. This infonnation may be stored in a read only
`memory (ROM). or in a nonvolatiie memory which can be
`written to only a single time. The invention further provides
`improved engagement structures for coupling robotic surgi-
`cal tools with manipulator structures.
`
`31 Claims. 22 Drawing Sheets
`
`
`
`IS 1007
`
`IS 1007
`
`1
`
`

`

`US 7,524,320 B2
`
`Page 2
`
`Us. PATENT DOCUMENTS
`
`4.149.278 A
`4281-447 A
`4332.066 A
`43577998 A
`4.386.933 A
`47456950 A
`4.486.928 A
`4.500.055 A
`4.511.305 A
`4.512.709 A
`4306.372 A
`4.710.093 A
`4.7447363 A
`4351.925 A
`47755375 A
`4393-053 A
`4.809.747 A
`4.830569 A
`47833-198 A
`4.837.703 A
`4338-545 A
`4943-939 A
`4.979.949 A
`47996-975 A
`5.018.266 A
`5373-149 A
`5.086.401 A
`5,143.453 A
`5.154.717 A
`5.155.693 A
`5.174.300 A
`5.184.601 A
`5.217.003 A
`
`5.236.432 A
`5.243.266 A
`5.255.429 A
`5.257.998 A
`5.271.384 A
`5.294.209 A
`5305203 A
`5.312.212 A
`5.313.935 A
`5.337.732 A
`53397799 A
`5.343.335 A
`5.354.314 A
`5355343 A
`5359-993 A
`5372-147 A
`5397323 A
`51399-951 A
`53109-257 A
`5.402.801 A
`51403-319 A
`5517310 A
`SAN-097 A
`51451-358 A
`55207573 A
`5.617.857 A
`5.624.398 A
`5539-431 A
`51531-973 A
`5549955 A
`5590535 A
`5.695.500 A
`5.695.501 A
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`47"1985 Hemekeseta].
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`1271987 Zimmeretal.
`511938 1135509
`671988 ’l'ontarra
`8-"1938 Hodge
`1311933 ZUCCW clal-
`371989 Cholyetal-
`571989 13717117078
`571939 Alikhan
`5-"1989 Kakazu elal-
`511990 Walters
`“”1990 Hoover
`12.11990 513966.111 81:11.
`311991 Nakmmm
`53199] Hutchinsone‘tal.
`1"]992 KWOh
`211992 Glassmanetal.
`931992 Weynant I'lée Girones
`[071992 Matsen. 111101211.
`1071992 All'maycrctal.
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`271993 Pittman
`671993 Wiik
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`871993 Maison. 1110181.
`971993 Kasagmni eta].
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`1171993 Otaela].
`1271993 McEwen 61.11.
`371994 Naka e161.
`4.1994 Raab
`571994 Naumec
`5-"1994 Kortenbach et a].
`871994 Grundfostctal.
`351994 K311951317
`871994 Joskowicz et al-
`1071994 1160mm.
`[011994 T653!
`1111994 Slateret 31-
`1211994 L‘11-1‘L""3|3- 11" eta].
`3"1995 Taylor
`35-1995 Lavallce et 31'
`31995 Beach Ct 3-17
`4-"1995 Taylor
`4-"1995 Mazsen. III 31 1'1-
`551995 Funda ‘3‘ 3L
`671995 Depp
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`541995 Heckeie et a].
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`551-997 Taylor
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`
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`272002 Cooper
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`6.370.411 Bl
`672002 Ramans €1.31.
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`772002 Nicmeycreta].
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`5.491.701 32
`492003 Lee etal.
`6.554.844 132*
`372004 Waagcta].
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`5355.571 BE
`372002 Tierney e161.
`200270032452 A1
`FOREIGN PATENT DOCUMENTS
`.
`.
`
`“’0
`“’0
`W9
`“’0
`“’0
`“’0
`W0
`W0
`
`“’0 99.25157
`“’0 95-45396
`“’0 95130954
`W0 9599944
`“’0 97729710
`“’0 93-95555
`W099750'1'Zl
`“’0 00733755
`
`“"1994
`51.1995
`““1995
`”"1995
`311997
`57'3")“
`1071999
`673900
`
`OTHER PUBLICATIONS
`Madhanietal..“‘1‘hcblack fa]con:Atclcopcrated surgicalinstnunent
`for minimally invasive surgery" (submitted 16 11205 1998}9 pages
`mm.
`Meyer. T.H.. Thesis entitled ”The design of an integrated hand and
`wrist mechanism" formsterof Science in Mechanical Engineering
`at the Massachusetts Institute of Technology (1992)pp. 1-106.
`Neisius et 11].. “Roboticmanipulator forendoscopic handling ofsun
`gica] effectors and cameras“ Proceedings 01‘ the First International
`Symposium on Medical Robotics and Computer Assisted Surgery.
`vol.2.Workshop(PartI&11)-Session\r'1.pp.169-175.
`Salisbury. J.K.. “Kinematic and force analysis ol’articuiated hands”
`Department of Computer Science. Stanford University. Report No.
`STAN-CS—SZ-‘JZI 71982) Chapter 9. pp. 67.77.
`ThJ'ing. "Robots and telechirs: Manipulators with memory; remote
`manipulators; machine limbs for the handicapped” (1993) M.W.
`Thrinngliis Horwood 1.111. pp. 9—11. 122—131. 194—195. 235—257.
`374.3179.
`“'l'ask 2:Miniatl.1rcend efiector-- A preliminary design" pp. 32-47.
`V'enul. Jean and Coet't'et. Philippe Coit’fel; “Robot Technology; vol.
`3A Teleoperation and Robotics Evolution and Development”; 1986;
`Prentice-Hall. inc; Englewood Cliffs.N.J.
`
`*cited by examiner
`
`2
`
`

`

`US. Patent
`
`Apr. 28,2009
`
`Sheetl of 22
`
`US 7,524,320 32
`
`150
`
`/ID
`
`,1
`
`
`
`3
`
`

`

`
`
`4
`
`

`

`US. Patent
`
`Apr. 28,2009
`
`Sheet 3 of 22
`
`US 7,524,320 32
`
`
`
`FIG. 2A.
`
`5
`
`

`

`US. Patent
`
`Apr. 28,2009
`
`Sheet 4 of 22
`
`US 7,524,320 32
`
`
`
`
`6
`
`

`

`US. Patent
`
`Apr. 28, 2009
`
`Sheet 5 of 22
`
`US 7,524,320 B2
`
`
`
`7
`
`

`

`US. Patent
`
`Apr. 28, 2009
`
`Sheet 6 of 22
`
`US 7,524,320 B2
`
`
`
`
`
`8
`
`

`

`US. Patent
`
`Apr. 28, 2009
`
`Sheet 7 of 22
`
`US 7,524,320 B2
`
`
`
`9
`
`

`

`US. Patent
`
`Apr. 28,2009
`
`Sheet 8 of 22
`
`US 7,524,320 32
`
`FIG.4B.
`
`10
`
`10
`
`

`

`US. Patent
`
`Apr. 28,2009
`
`Sheet 9 of 22
`
`US 7,524,320 32
`
`
`
`11
`
`11
`
`

`

`US. Patent
`
`Apr. 28,2009
`
`Sheet 10 of 22
`
`US 7,524,320 32
`
`fl 4"“fifl’
`
`m,
`
`.0
`
`FIG: 5C
`
`
`
`12
`
`

`

`US. Patent
`
`Apr. 28, 2009
`
`Sheet 11 of 22
`
`US 7,524,320 B2
`
`
`
`13
`
`13
`
`

`

`US. Patent
`
`Apr. 28, 2009
`
`Sheet 12 of 22
`
`US 7,524,320 B2
`
`
`
`FIG: 7H.
`
`FIG 71."
`
`14
`
`14
`
`

`

`US. Patent
`
`Apr. 23, 2009
`
`Sheet 13 of 22
`
`US 7,524,320 B2
`
`
`
`15
`
`15
`
`

`

`US. Patent
`
`Apr. 28,2009
`
`Sheet 14 of 22
`
`US 7,524,320 32
`
`ELOOTI POE
`, 5“;
`I35) 535 -RED E37
`+
`
`-5, TOO-E! mm
`
`
`
`W!
`
`SHIELD"
`
`FORCE SENSOR :F I
`
`LE) £33
`,5“;
`-33, m---HAIJGELFBRI
`m, mam-mm
`SHIELD "
`'wg
`
`I47
`
`~ WWII-{film.m-
`
`T26
`
`TOOLEXPIOEO 3E3 523
`TOOLEXPTREED
`
`ROLLING LOOP
`
`BALM CHIP
`
`Ear
`macs SENSOR #2
`CARRIASEPGBMZ
`T44
`Os M52:
`0mg
`“”6”
`-5TERILE> mm-Irnfifi'fl[3’13” 18
`W WEI-mi—am12131,, E:--E
`'51-:32 33
`sum) ' F Tan
`DALLAS CHIP
`
`5,, 53
`“mo
`an. E liufiniwn-T
`(STERILEADAPTDRJ
`
`STEgflgtgmgw-
`3,33: mam-On-El
`-529
`M
`I
`I
`
`(W03
`LOOP an 3
`
`'43](OPTIONAL)
`
`RED
`TOOL-CHAR-sw >
`
`E45
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`TOOL-CHAN.8HDswap
`TOOL CHANGESW RED {ELIE}?!-
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`BU -EIE'-4 “1"
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`
`TOOLOOAOOE szTOH
`
`5‘“
`SLAVEOLOTOH- 51b “'5“
`BIT ELIE}?- J
`“"0 -
`
`SLAVE GLUTGHIHG SWITCH
`
`FIG 8.
`
`16
`
`16
`
`

`

`US. Patent
`
`Apr. 28,2009
`
`Sheet 15 of 22
`
`US 7,524,320 32
`
`
`
`FIG: 8A.
`
`17
`
`

`

`US. Patent
`
`Apr. 28
`
`9
`
`2009
`
`n
`
`US 7,524,320 B2
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`Hm2042
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`
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`037mmHmo<_mm<o
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`
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`
`(E
`
`(E
`
`on
`
`Nmr
`
`18
`
`18
`
`
`

`

`US. Patent
`
`Apr. 28,2009
`
`Sheet 17 of 22
`
`US 7,524,320 32
`
`
`MIDDLEMAN (CTP)
`
`
`SUPERVISOR (UMC)
`EXECUTES
`
`CONTREIESV‘QOG'CAL
`INSTRUCTIONS FROM
`
`
`
`
`
`SUPERVISOR
`
`
`
`
`
`PROCEDURE
`
`KERNEL (CTP AND CES)
`MANAGEMENT/DATA
`
`
`
`HANDLER (MDC)
`
`
`
`
`
`LOCAL TOOL
`
`
`DETECTION (RIA)
`
`
`FIG. 10.
`
`19
`
`19
`
`

`

`US. Patent
`
`Apr. 28, 2009
`
`Sheet 13 of 22
`
`US 7,524,320 132
`
`SEQUENCE FLOW
`
`DETAILED SEQUENCE
`BLOCKS
`
`147
`
`REED
`SWITCH
`OPEN
`
`
`
`REED
`SWITCH
`LOSED’
`
`
`
`H
`
`
`
`TO INDICATE CHANGE IN
`
`TOOL DALLAS
`
`PRESET‘
`
`TOOL DALLAS
`
`0T PRESENT*
`
`
`
`TOOL DALLAS
`
`TOOL DALLAS
`
`PRESET‘ @NOTPRESENT“
`
`FIG. 11.
`
`20
`
`- SIGNIFIES MESSAGE SENT @
`HARDWARE STATE ®
`
`
`
`CHECK
`
`FOR
`TOOL
`
`NO SA
`PRESENT
`
`
`
`
`
`20
`
`

`

`US. Patent
`
`Apr. 28,2009
`
`Sheet 19 of 22
`
`US 7,524,320 32
`
`POWER ON
`
` INITIALIZATION
`
`
`
` TOOL IS
`BEING INSERTED
`
`(S4)
`
`
`
`
`complete
`
`
`Sterile ad oter engaged
`
`TOOL IS
`
`OUT (82)
`
`Initialization
`
`
`
`Sadapter D hip
`
`
`
`
`ADAPTER
`
`STERILE
`
`OFF (31)
`
`111
`
`
`
`
`D = Dallas chip ( 1 = present, 0 = not present)
`E = End of use indicator (0 = Open. 1 = Shorted)
`R = Reed Switch ( 0: open, 1 = shorted)
`
`
`
`Events occur in DER order
`
`e.g. 101 means Dallas chip present. End of use
`indicator is open, Reed switch is closed}
`
`A=110,100,010.110, 101,111
`s=011,101,001
`0:001, 010. 011, 100. 101, 110. 111
`FIG. 12.
`
`
`
`Logging occurs if the situation
`
`persists for more than 1 second
`
`21
`
`21
`
`

`

`US. Patent
`
`Apr. 28,2009
`
`Sheet 20 of 22
`
`US 7,524,320 32
`
`
`
`
`
` TOOL
`CHANGE
`CHANGE
`
`TOOL
`
`
`
` 0'.
`CHANGE
`
`DONE
`
`
`
`
`TOOL
`
`CHANGE
`FOLLOW
`
`
`DONE
`CHK 1
`
`
`
`
`
` TOOL
`FOLLOW
`
`CHK 2
`
`
`
`FIG. 13.
`
`22
`
`22
`
`

`

`US. Patent
`
`Apr. 28,2009
`
`Sheet 21 of 22
`
`US 7,524,320 32
`
`
`
`23
`
`

`

`US. Patent
`
`Apr. 28,2009
`
`Sheet 22 of 22
`
`US 7,524,320 32
`
`166
`
`ALGORITHM
`
`162
`
`
`
`1
`
`64
`
`TOOL PRODUCTION
`
`TOOL COMPATIBILITY VERIFICATION
`
`166
`
`ALGORITHM
`
`
`
`
`170
`
`TOOL
`
`PROCESSOR
`
`FIG. 15.
`
`24
`
`24
`
`

`

`US ?.524,320 B2
`
`1
`MECHANICAL ACTUATOR INTERFACE
`SYSTEM FOR ROBOTIC SURGICAL TOOLS
`
`C ROSS-REFERENC ES TO RELATED
`APPLlCAI‘IONS
`
`The present application is a continuation of U.S. patent
`application Ser. No. 09l929.453 filed on Aug. 13. 2001. and is
`a divisional application of U.S. patent application Ser. No.
`091759.542 filed Jan. 12.2001. now U.S. Pat. No. 6.491.701.
`which is a continuation application of U.S. patent application
`Ser. No. 0914 I 8.726 filed Dec. 6. 1999. and in turn also claims
`
`10
`
`priority to U.S. Provisional Patent Application No. 603'111.
`713 filed on Dec. 8. 1998; U.S. patent application Ser. No.
`091398.958 filed Sep. ]7. 1999. now US. Pat. No. 6.394.998;
`and U .S. Provisional Patent Application No. 601'1 16.844 filed
`on Jan. 2. 1999. entitled “Surgical Tools For Use In Mini-
`mally Invasive Telesurgical Applications“. The entirety ofthe
`above-referenced applications is herein incorporated by ref-
`crence.
`
`This application also incorporates by references the fol—
`lowing U.S. Design patent application Ser. Nos. 291097.544
`filed on Dec. 8. 1998, entitled “Portion OfAn Interface For A
`Medical Instrument”: 291097.552 filed on Dec. 8. 1998.
`entitled “Interface For A Medical Instrument“: 291097.550
`filed on Dec. 8. 1998. entitled “Portion Of An Adaptor For A
`Medical Instrument": and 291097.551 filed on Dec. 8. 1998.
`entitled “Adaptor For A Medical Instrument".
`
`BACKGROUND OF ‘fl-lli INVENTION
`
`3t]
`
`This invention relates to robotically assisted surgery. and
`more particularly provides surgical
`tools having improved
`mechanical andfor data interface capabilities to enhance the
`safety. accuracy. and speed of minimally invasive and other
`robotically enhanced surgical procedures.
`In robotically assisted surgery, the surgeon typically oper-
`ates a master controller to remotely control the motion of
`surgical instruments at the surgical site. The controller may be
`separated from the patient by a significant distance {e.g.,
`across the operating rootu. in a different room. or in a com-
`pletely different building than the patient). Altematively. a
`controller may be positioned quite near the patient in the
`operating room. Regardless.
`the controller will
`typically
`include one or more hand input devices (such as joysticks.
`exoskeletol gloves. master manipulators. or the like) which
`are coupled by a servo mechanism to the surgical instrument.
`More specifically. servo motors move a manipulator or
`“slave" supporting the surgical instrument based on the sur—
`geon‘s manipulation of the hand input devices. During an
`operation. the surgeon may employ. via the robotic surgery
`system. a variety of surgical instruments such as tissue grasp-
`ers. needle drivers. electrosurgical cautery probes. etc. Each
`of these structures perfonns functions for the surgeon. for
`example. holding or driving a needle. grasping a blood vessel,
`or dissecting, cauterizing. or coagulating tissue.
`This new method of performing robotic surgery has. of
`course. created many new challenges. One such challenge is
`that a surgeon will typically employ a significant number of
`different surgical instruments during each surgical procedure.
`The number of independent surgical manipulators will often
`be limited due to space constraints and cost. Additionally.
`patient trauma can generally be reduced by eliminating the
`number oftools used at any given time. More specifically. in
`minimally invasive procedures. the number ofentry ports into
`a patient is generally limited because of space constraints. as
`well as a desire to avoid unnecessary incisions in the patient.
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`Hence. a number of different surgical instruments will typi-
`cally be introduced through the same trocar sleeve into the
`abdomen during.
`for example.
`laparoscopic procedures.
`Likewise. in open surgery. there is typically not enough room
`adjacent the surgical site to position more than a few surgical
`manipulators. particularly where each lnanipulatorllool coin-
`bination has a relatively large range of motion. As a result. a
`number of surgical instruments will often be attached and
`detached from a single instrument holder oi‘a manipulator
`during an operation.
`Published PCT application W098l25666. filed on Dec. 10.
`1997 and assigned to the present assignee (the full disclosure
`of which is incorrxtratmi herein by reference) describes a
`Multicomponent Telepresence System and Method which
`significantly improves the safety and speed with which
`robotic surgical tools can be removed and replaced during a
`surgical procedure. While this
`represents a
`significant
`advancement of the art. as is often trtle. still further improve-
`ments would be desirable. In particular. each tool change
`which occurs during a surgical procedure increases the over-
`all surgery time. While still further improvements in the
`tnechani cal toolt'mani pulator interface may help reduce a por~
`tion of this tool change time. work in connection with the
`present invention has shown that the mechanical removal and
`replacement of the tool tnay represent only one portion of the
`total interruption for a tool change. U.3. Pat. No. 5.400.267
`describes a memory feature for electrically powered medical
`equipment. and is also incorporated herein by reference.
`As more and more different surgical tools are provided for
`use with a robotic system. the differences between the tool
`stmctures {and the interaction between the too] and the other
`components of the robotic system) become more pro-
`nounced. Many of these surgical tools will have one or more
`degrees ofmotion between the surgical end elfecttirs and the
`proximal interface which engages the tool to the holder ofthe
`manipulator. The desired andfor practicable ranges ofmotion
`for an electrosurgical scalpel may be significantly different
`than those of a clip applier. for example. Work in connection
`with the present invention has found that even after a tool is
`properly placed on the surgical manipulator.
`the time
`involved in reconfiguring the robotic system to take advan-
`tage of a different tool. and to perfect the master controller’s
`effective control over the degrees of motion of the tool. may
`add significantly to the total tool change delay.
`In light of the above.
`it would be desirable to provide
`improved robotic surgery tools. systems. and method.
`It
`would further be desirable to provide techniques for reducing
`the total delay associated with each tool change. It would be
`especially desirable if these enhanced. and often more rapid.
`robotic tool change techniques resulted in still
`further
`improvement in the safety and reliability of these promising
`surgical systems.
`
`BRIEF SUMMARY OF THE INVENTION
`
`The present invention generally provides improved robotic
`surgical devices. systems. and methods for preparing for and
`performing robotic surgery. The robotic tools of the present
`invention will often make use ofa memory structure mounted
`on a tool. manipulator arm. or movable support structure. The
`memory can. for example. perform a number of important
`functions when a tool is loaded on the tool manipulator: first.
`the memory can provide a signal verifying that the tool is
`compatible with that particular robotic system. Secondly. the
`tool memory may identify the tool—type (whether it is a scal—
`pel. needle grasper, jaws. scissors. clip applicr. electrocautery
`blade. or the like) to the robotic system so that the robotic
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`system can reconfigure its programming to take full advann
`tagc of the tools’ specialized capabilities. This tool-type data
`may simply be an identification signal referencing further
`data in a lo ok- up ta ble ofthe robotic system. Alternatively. the
`tool-type signal provided by the too] may define the tool
`characteristics in sufficient detail to allow reconfiguration of
`the robotic programming without having to resort to an exter—
`nal table. Thirdly. the memory of the too] may indicate too]-
`specific information, including {for example) measured cali-
`bration offsets indicating misalignment between the tool
`drive system and the tool end effector elements, tool life data
`[such as the number of titnes the tool has been loaded onto a
`surgical system.
`the number of surgical procedures pe -
`formed with the tool. andfor the total time the tools has been
`used). or the like. The information may be stored in some
`form of non-volatile memory such as onetime program-
`mable EPROM. Flash EI’ROM. fiEPROM. battery-backed-
`up SRAM, or similar memory technology where data can be
`updated and retained in either a serial or random access
`method. or with any ofa wide variety ofalternative hardware.
`firmware. or software. The invention further provides
`improved engagement structures for coupling robotic surgi—
`cal tools with manipulator structures.
`In a first aspect, the invention provides a robotic surgical
`tool for use in a robotic surgical system. The robotic surgical
`system has a processor which directs movement of a tool
`holder. The tool comprises a probe having a proximal end and
`a distal end. A surgical end effector is disposed adjacent the
`distal end ofthe probe. An interface is disposed adjacent to the
`proximal end of the probe. The interface can be releasably
`coupled with the tool holder. Circuitry is mounted on the
`probe. The circuitry defines a signal for transmitting to the
`processor so as to indicate compatibility of the too] with the
`system.
`The tool will often comprise a surgical instrument suitable
`for manipulating tissue. an endoscope or other image capture
`device. or the like. Preferably. the signal will comprise unique
`tool identifier data. The processor of the robotic surgical
`system may include programming to manipulate the tool
`identifier according toapre-deterrnined function or algorithm
`so as to derive vet-i ficalion data. The signal transmitted to the
`processor will often include the verification data. Altemative
`compatibility signals may include a signal which is listed in a
`table accessible to the processor. an arbitrary compatibility
`data string. or the like.
`In another aspect, the invention provides a robotic surgical
`component for use in a robotic surgical system having a
`processor and a component holder. The component comprises
`a component body having an interface mountable to the com—
`ponent holder. The body supports a surgical end effector. and
`a drive system is coupled to the body for moving the end
`effector per commands from the processor. Circuitry is
`mounted on the body and defines a signal for transmitting to
`the processor. The signal may indicate compatibility of the
`component wi lh the system. may define a component type of
`the component. may indicate coupling of the component to
`the system, and!or may indicate calibration ofthe component.
`Typically. the component will comprise a surgical tool. a
`manipulator arm. a pre-positioning linkage supporting the
`manipulator arm, or the like.
`In another aspect. the invention provides a method for
`installing a robotic surgical component in a robotic surgical
`system. The method comprises mounting the component to a
`component holder. A signal is transmitted from the compo—
`nent to a processor of the robotic surgical system. The com—
`ponent is articulated in response to the signal per commands
`of the processor.
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`In many embodiments. compatibility of the component
`with the robotic surgical system will be verified using the
`signal transmitted from the component to the processor. This
`can be accomplished by providing unique identification data
`on the component. and deriving verification data from the
`identification data according to an algorithm. The verification
`data is stored with a memory of the component. the sigtal
`transmitted to the processor including both the identification
`and verification data. The algorithm may then be performed
`on the transmitted unique identification data with the proces-
`sor, and the results compared with the verification data.
`Advantageously. this method can take advantage of unique
`identification data which is ofien unalterably stored in a
`memory of commercially available integrated circuits.
`In another aspect. the invention provides a robotic surgical
`too] for use in robotic surgical systems having a processor.
`The tool comprises a shaft having a proximal end and a distal
`end. A surgical end effector is disposed adjacent the distal end
`of the shaft. The end effector has a plurality of degrees of
`motion relative to the proximal end. An interface is disposed
`adjacent the proximal end of the shaft. The interface cart be
`releasably coupled with a robotic probe holder. The interface
`comprises a plurality of driven elements. A plurality of tool
`drive systems couple the driven elements to the degrees of
`motion ofthe end effector. The tool drive system has calibra-
`tion offsets between a nominal relative position of the end
`effector and the driven elements. and a measured relative
`position of the end effector and driven elements. A memory
`stores data indicating the offsets. The memory is coupled to
`the interface so as to transmit the offsets to the processor.
`In yet another aspect, the invention provides a robotic
`surgical system comprising a plurality of tools of different
`tool-types. Each tool comprises an elongate shaft with a
`cross-section suitable for introduction into an internal surgi-
`cal site within a patient body via a minimally invasive open—
`ing. A distal surgical end effector is coupled to the shaft by at
`least one joint. The joint is drivingly coupled to a proximal
`interface by a tool drive system. Circuitry ofthe tool transmits
`a tool-type via the interface. The tool types may optionally
`differ in at least one characteristic such asjoint geometry. end
`effector geometry. drive system characteristics. end effector
`or drive system strength, or the like. The system also includes
`a robotic manipulator including a linkage supporting a tool
`holder. The tool holder releasably receives the interface. A
`manipulator drive motor drivingly engages the linkage so as
`to move the tool holder relative to the opening and position
`the site It within the surgical site. A tool drive motor is coupled
`to the tool holder so as to drivingly engage the tool drive
`system and articulate thejoint. A processor is coupled to the
`too] holder. The processor has programming that effects a
`desired movement of the end effector by transmitting drive
`signals to the tool drive motors of the manipulator. The pro-
`cessor reconfigures the program for the different joint geom-
`etries based on the tool-type signals.
`In another aspect. the invention provides a robotic surgical
`system comprising a surgical tool having a surgical end effec~
`tor and an interface. A manipulator assembly has a base and a
`tool holder for releasably engaging the interface. A plurality
`of tool engagement sensors are coupled to the tool holder.
`Each tool sensor produces a signal when the interface engages
`the holder. A processor is coupled to the tool engagement
`sensors. The processor has a tool change mode and a tissue
`manipulation mode. The processor requires tool signals from
`each of the sensors before changing the tool change mode to
`the tissue manipulation mode. The processor remains in the
`tissue manipulation mode when at least one, but not all. of the
`tool signals is lost.
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`The tools used in robotic surgery will be subjected to
`significant structural stress during use. The stress may result
`in temporary loss of an engagement signal from an engage-
`ment sensor. By providing at least two. and preferably three
`engagement sensors.
`the surgical procedure can continue
`safely with the loss of an engagement signal from an indi-
`vidual sensor so long as the system can still verify proper
`engagement between the manipulator and tool. This arrange-
`ment results in a robust too] engagement sensing system that
`avoids frequent delays during the surgical procedure as might
`occtlr from the loss of an individual signal.
`in yet another aspect. the invention provides a robotic
`surgical system comprising a manipulator assembly having a
`base and tool holder which moves relative to the base. The
`
`tool holder has a plurality of drive elements. A sterile drape
`covers at least a portion of the manipulator. A sterile tool has
`a proximal interface and distal end effector. The distal end
`effector has a plurality of degrees of motion relative to the
`proximal interface. The degrees of motion are coupled to
`drive elements of the interface. An adapter is disposed adja-
`cent the sterile drape between the holder and the interface.
`The adapter comprises a plurality of movable bodies. Each
`movable body has a first surface driven by the drive elements
`of the holder, and a second surface driving the driven ele-
`ments of the tool.
`
`in yet another aspect. the invention provides a robotic
`surgical tool for use with a robotic manipulator having a tool
`holder. The tool holder has magnetically actuatable circuitry.
`The tool comprises a probe having a proximal end and a distal
`end. A surgical end effector is disposed adjacent the distal end
`of the probe. An interface adjacent the proximal end of the
`probe is releasably ooupleable with the holder. The interface
`comprises a magnet positioned so as to actuate the circuitry of
`the holder.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG. 1 illustrates a robotic surgical procedure in which a
`surgeon at a master station directs movement of robotic sur-
`gical tools elfected by a slave manipulator. and shows an
`assistant preparing to change a tool mounted to a tool holder
`of the slave.
`
`FIG. 2 is a perspective view of a robotic surgical arm cart
`system in which a series of passive set-up joints support
`robotically actuated manipulators (typically, the center arm
`would support a camera).
`FIG. 2A is a perspective view of a robotic surgical manipu-
`lator for use in the cart system of FIG. 2.
`FIGS. 2B and C are side and front views. respectively, of
`the linkage ofthe robotic manipulator ofFIG. 2, showing how
`the manipulator maintains a remote center ofrotation along a
`shaft of the surgical tool.
`FIGS. 3 and 3A are perspective views of exemplary cart
`structures with positioning linkages which support
`the
`robotic manipulators in the system of FIG. 2.
`FIG. 4 is a perspective view of an exemplary tool according
`to the principles of the present invention.
`FIGS. 4A and B are schematic views of alternative drive
`systems for the tool of FIG. 4.
`FIGS. 5A through H are illustrations ofa variety ofsurgical
`end effectors ofdiflering tool-types.
`FIG. 6 illustrates the mechanical and electrical interface of
`the tool of FIG. 4.
`
`FIGS. 7A through E illustrate an adapter for coupling the
`interface of FIG. 6 to the surgical manipulator.
`FIGS. 7G through 1 illustrate the adapter of FIGS. 7A
`through E mounted to a holder or carriage of the manipulator.
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`FIGS. 7.] through L illustrate the holder, its driving ele
`ments. and its electrical contacts.
`FIG. 8 is a wiring diagram for the tool of FIG. 4. the adapter
`of FIG. “TA-E, and related components of the robotic system.
`FIGS. 8A and B are rear and front views of the master
`console. respectively.
`FIG. 9 is a functional block diagram schematically illus—
`trating the signal path hardware of the tool change system.
`FIG. 10 is a schematic diagram illustrating the interaction
`between the software modules related to too] change.
`FIG. 11 is a logic flow chart illustrating an exemplary
`method for sensing engagement ofa tool with the manipula-
`[0]:
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`FIG. 12 is a flow diagram illustrating how the tool engage—
`ment signals are used to change the operating state of the
`robotic system.
`FIG. 13 illustrates the tool engagement method steps ini-
`tiated by the processor in response to a change in operating
`state during tool changes.
`FIGS. 14A through (7 illustrate mounting of the adapter of
`FIGS. 7A through E to a manipulator arm, and of mounting
`the tool of FIG. 4 onto the adapter.
`FIG. 15 schematically illustrates an exemplary tool cont-
`patibility verification algorithm according to the principles of
`the present invention.
`
`I)l.£'l'.1\1l.lfli) DESCRIPTION 01-" THE lNVlZNTIUN
`
`The present invention provides robotic surgery systems.
`devices. and methods. Robotic surgery will generally involve
`the use of multiple robotic arms. One or more of the robotic
`arms will often support a surgical tool which may be articu-
`lated (such as jaws, scissors. graspers, needle holders. micro-
`dissectors. staple appliers. tackers. suction;If irrigation tools.
`clip appliers. or the like) or non—articulated (such as cutting
`blades. cautery probes. irrigators. catheters, suction orifices.
`or the like). One or more ofthe robotic arms will often be used
`to support one or more surgical image capture devices such as
`an endoscope (which may be Euly of the variety of structures
`such as a laparoscope. an arthroscope. a hysteroscope, or the
`like). or optionally. sortie other imaging modality (such as
`ultrasound, fluoroscopy. magnetic resonance imaging. or the
`like). Typically. the robotic arms will support at least two
`surgical tools corresponding to the two hands of a surgeon and
`one optical image capture device.
`The present invention will find application in a variety of
`surgical procedures. The most immediate applications will be
`to improve existing mi